Diaphragm with segmented insert

ABSTRACT

A flush valve diaphragm of a flush valve includes a body having a segmented insert within a flexible body portion and a central passageway. The body further includes a peripheral sealing portion with the flexible body portion within the peripheral sealing portion. The peripheral sealing portion can include an integral filter, an exit chamber and a bypass arrangement, such that water flowing through the filter flows through the bypass arrangement. The integral filter version will retard clogging of the bypass arrangement. The segmented insert includes a plurality of trapezoidal members with outward protrusions. The plurality of trapezoidal members are connected to each other on their outermost edge by a runner.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser.No. 60/878,478 filed Jan. 3, 2007 and titled “DIAPHRAGM WITH SEGMENTEDINSERT.” The disclosure and specification of U.S. ProvisionalApplication Ser. No. 60/878,478 is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to flexible diaphragms used in flushvalves, and more particularly, to flexible diaphragms with a segmentedinsert used in flush valves.

2. Description of Present Technology

Flush valves in water closets, urinals, and other plumbing devices,which utilize a flexible diaphragm to establish, and to seal off, theconnection between the inlet and outlet sides of the flush valve arewell-known in the art. Typically, the diaphragm is made of anelastomeric material, such as rubber, and includes a bypass orifice,which provides fluid communication between the inlet side of the flushvalve and an upper chamber of the flush valve. An example of a typicaldiaphragm is shown in FIG. 1 of U.S. Pat. No. 5,232,194 to Saadi et al.(hereinafter also referred to as the “Saadi patent”); the disclosure ofthe Saadi patent is incorporated herein by reference.

The time cycle during which fluid, e.g. water, flows through the flushvalve varies depending on the time it takes for a pressure drop to occurbetween the opposite sides of the diaphragm due to water passing througha bypass orifice into the upper chamber of the flush valve.Specifically, a pressure difference across the diaphragm causes water topass through the flush valve for a fixed period of time when the flushvalve is activated. As can now be appreciated, the bypass orifice of thediaphragm-type flush valves acts as a timing device. A detaileddiscussion of the operation of a diaphragm used with a flush valve canbe found in column 1, lines 11-58 of the Saadi patent.

Recently, there has been some interest in filtering the water passingaround the diaphragm to prevent clogging of the bypass orifice, whichcould undesirably effect the time period during which the flush valve isactivated and/or the time of the flush valve refill cycle. U.S. Pat. No.6,923,425 B2 to Verdecchia (hereinafter also referred to as the“Verdecchia patent”), which patent is hereby incorporated by reference,discloses a filtration system for preventing the clogging of the bypassorifice. In general, the Verdecchia patent discloses a flush valvediaphragm that includes a body portion and a peripheral sealing portionwith the peripheral sealing portion including an integral filter. Theintegral filter prevents clogging of the bypass orifice. Although thepresently available diaphragms are acceptable to prevent clogging of thebypass orifice, there are limitations. More particularly, the presentlyavailable diaphragms include a plurality of bendable or flexible metalinserts embedded in a rubber body to maintain the contour of thediaphragm as the upper surface of the diaphragm transitions from aconcave shape to a convex shape, and the bottom surface, transitionsfrom a convex shape to a concave shape, as the flush valve goes from theclosed position to the open position.

Although metal plates are acceptable for use as inserts in flexiblediaphragms of flush valves, it is appreciated by those skilled in theart, that it would be advantageous to have flexible diaphragms having abendable insert of a different material that is lighter in weight than aplurality of metal inserts, and flexible diaphragms that are lessexpensive than diaphragms having a plurality of metal inserts.

SUMMARY OF THE INVENTION

This invention relates to a flush valve diaphragm having, among otherthings, a body having a flexible body portion and a segmented insertwithin the flexible body portion. The body includes, among other things,a central passageway; a peripheral sealing portion comprising a sealingring extending along the periphery of the body, the sealing portion witha thickness greater than the thickness of portion of the body within thesealing ring, wherein the flexible body portion is within the peripheralsealing portion; a first integral ring on a first side of the bodyradially spaced from the sealing ring; a second integral ring on anopposite second side of the body radially spaced from the sealing ring;an integral filter integrally formed in the body located between thesealing ring and the first integral ring between the sealing ring andthe second integral ring, and a bypass chamber positioned between thefirst integral ring and the sealing ring; an exit chamber positionedbetween the second integral ring and the sealing ring; a bypass orificeextending from and allowing fluid communication between the bypasschamber and the exit chamber. The segmented insert includes, among otherthings, a plurality of trapezoidal members with protrusions extendingoutward from a major surface of the trapezoidal members, wherein theplurality of trapezoidal members are connected to each other on theiroutermost edge by a runner.

The present invention is also directed to an improvement to a flushvalve diaphragm of the type having a flexible rubber body and a metalinsert embedded in the rubber body. The flush valve diaphragm is usedwith water closets and urinals, which utilize the flexible diaphragm toestablish, and to seal off, the connection between the inlet and outletsides of a flush valve. The improvement includes, among other things,the flush valve diaphragm including, among other things, a plasticsegmented insert embedded in a body made of a thermoplastic elastomer.The plastic segmented insert, includes, among other things, a pluralityof trapezoidal members with protrusions extending outward from a majorsurface of the trapezoidal members, wherein the plurality of trapezoidalmembers are connected to each other on their outermost edge by a runner.

The advantages of the present invention will be clarified in thedescription of the preferred embodiment taken together with the attacheddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial sectional elevational view of a flush valve assemblyin a closed position incorporating features of the invention;

FIG. 2 is a sectional elevational view of a portion of the flush valveassembly shown in FIG. 1 in an open position;

FIG. 3 is a bottom plan view having portions removed for purposes ofclarity of a flush valve diaphragm incorporating features of theinvention;

FIG. 4 is a top plan view having portions removed for purposes ofclarity of the flush valve diaphragm shown in FIG. 2;

FIG. 5 is a section taken along the lines 5-5 shown in FIG. 4;

FIG. 6 is an elevational view partially in section of a portion of aflush valve taken along lines 6-6 shown in FIG. 3

FIG. 7 is an elevational view partially in section of a portion of thediaphragm taken along lines 7-7 shown in FIG. 3;

FIG. 8 is a partial perspective view of a circumferential edge portionof the diaphragm shown in FIG. 4;

FIG. 9 is a top plan view of a non-limited embodiment of a segmentedinsert of the present invention;

FIG. 10 is a sectional side view taken along lines 10-10 of FIG. 9;

FIG. 11 is a top plan view of a second embodiment of a segmented insertmade in accordance with the present invention;

FIG. 12 is a sectional side view taken along lines 12-12 of FIG. 11; and

FIG. 13 is a sectional side view taken along lines 13-13 of FIG. 11.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

As used herein, spatial or directional terms, such as “inner”, “outer”,“left”, “right”, “up”, “down”, “horizontal”, “vertical”, and the like,relate to the invention as it is shown in the drawing figures. However,it is to be understood that the invention can assume various alternativeorientations and, accordingly, such terms are not to be considered aslimiting. Further, all numbers expressing dimensions, physicalcharacteristics, and so forth, used in the specification and claims areto be understood as being modified in all instances by the term “about”.Accordingly, unless indicated to the contrary, the numerical values setforth in the following specification and claims can vary depending uponthe desired properties sought to be obtained by the present invention.At the very least, and not as an attempt to limit the application of thedoctrine of equivalents to the scope of the claims, each numericalparameter should at least be construed in light of the number ofreported significant digits and by applying ordinary roundingtechniques. Moreover, all ranges disclosed herein are to be understoodto encompass any and all subranges subsumed therein. For example, astated range of “1 to 10” should be considered to include any and allsubranges between (and inclusive of) the minimum value of 1 and themaximum value of 10; that is, all subranges beginning with a minimumvalue of 1 or more and ending with a maximum value of 10 or less, e.g.,1 to 6.7, or 3.2 to 8.1, or 5.5 to 10.

Before discussing non-limiting embodiments of the invention, it isunderstood that the invention is not limited in its application to thedetails of the particular non-limiting embodiments shown and discussedherein since the invention is capable of other embodiments. Further, theterminology used herein to discuss the invention is for the purpose ofdescription and is not of limitation. Still further, unless indicatedotherwise, in the following discussion like numbers refer to likeelements.

The present invention is directed to a flexible diaphragm having aflexible body and a segmented insert embedded in the flexible body foruse in a flush valve, for example but not limiting to the invention, aflush valve of the type disclosed in the Verdecchia patent and shown inFIG. 1. For a better appreciation of the invention, the discussion willfirst be directed to the major components of the flush valve; will thenbe directed to the features of the outer surface of the flexible body ofthe diaphragm having the segmented insert of the invention; willthereafter be directed to the operation of the flush valve, and willlastly be directed to the features of the segmented insert of theinvention embedded in the flexible body of the diaphragm.

As shown in FIG. 1, the flush valve 10 includes a valve body 12 havingan inlet opening 14, an outlet opening 16, a flush valve diaphragmassembly 18, movable to a closing position on valve seat 20 positionedbetween the inlet opening 14 and the outlet opening 16 to stop flow,e.g. water flow between inlet opening 14 and outlet opening 16. Theflush valve diaphragm assembly 18 includes a flexible diaphragm 22incorporating features of the invention peripherally attached to abarrel slide 24. A pressure chamber 26 is defined above the flexiblediaphragm 22 for holding the flush valve diaphragm assembly 18 on thevalve seat 20. Referring to FIGS. 1 and 2, the flush valve 10 furtherincludes a barrel 78 receiving the barrel slide 24, and a top cap 80.The top cap 80 is threadably secured to valve body 12. A handle 82(shown in FIG. 1) is provided in the valve body 12 to move the barrelslide 24 toward the top cap 80 to activate the flush valve diaphragmassembly 18, for example but not limited to the manner disclosed in theSaadi patent.

With continued reference to FIGS. 1 and 2, the barrel slide 24 issecured to flexible diaphragm 22 through a locking member 90. In onenon-limiting embodiment of the invention, the locking member 90 isthreadably received by the barrel slide 24, thereby sandwiching aportion of diaphragm 22 between lip 92 on the barrel slide 24 and thelocking member 90. The flush valve diaphragm assembly 18 can also bemolded or formed as a single unitary piece.

An inner cover 100 is provided and positioned inwardly and adjacent tothe top cap 80. A relief valve or trip mechanism 104 is provided andpositioned adjacent to the locking member 90 threaded to the barrelslide 24. The relief valve or trip mechanism 104 rests on the lockingmember 90 and is tripped through handle 82 in a manner well known in theart, such as, but not limited to that disclosed in the Saadi patent. Therelief valve 104 includes an upper circular sealing disk 122 and anelongated stem 106 attached thereto which co-acts with the handle 82.

The discussion is now directed to the configuration of the diaphragm 22having features of the invention. Referring to FIGS. 3 and 4, in anon-limiting embodiment of the invention, the flexible diaphragm 22includes a flexible body 27 having a segmented insert 29 of theinvention. The invention is not limited to the outer configuration ofthe flexible body 27, and any outer configuration of a flexible body ofa diaphragm of a flush valve known in the art can be used with thesegmented insert 29 of the invention. In one non-limiting embodiment ofthe invention, the body 27 has the outer configuration of the diaphragmdisclosed in the Verdecchia patent. More particularly, the flexible body27 of the diaphragm 22 has a body portion 28 and a peripheral sealingportion 30. The body portion 28 has a central passageway 32. Theperipheral sealing portion 30 includes a sealing ring 34 with athickness greater than the body portion 28 extending along the peripheryof the flexible diaphragm 22 (see also FIG. 4). The body 27 of theflexible diaphragm 22 also includes a first integral ring 36 (shown inFIG. 3) on a first side 38 of the flexible diaphragm 22 radially spacedfrom the sealing ring 34 (shown in FIG. 3). A second integral ring 40(shown in FIG. 4) on a second side 42 of the flexible diaphragm 22 isradially spaced from the sealing ring 34. An integral filter 44 islocated between the sealing ring 34 and the first integral ring 36, andbetween the sealing ring 34 and the second integral ring 40. A bypasschamber 46 is positioned between the first integral ring 36 and thesealing ring 34 (see FIG. 3). An exit chamber 48 is positioned betweenthe second integral ring 40 and the sealing ring 34 (see FIG. 4). Atleast one bypass orifice 50 (see FIGS. 5 and 6) extends from and allowsfluid communication between the bypass chamber 46 and the exit chamber48. The bypass orifice 50 connects the inlet opening 14 and the pressurechamber 26. The integral filter 44 includes a plurality ofcircumferentially spaced filter passages 54 defined in the flexiblediaphragm 22 (see FIG. 7). The filter passages 54 extend from the firstside 38 of the diaphragm 22, through the diaphragm 22, to the secondside 42 of the diaphragm 22.

The first side or the bottom side 38 of the flexible diaphragm 22 asmounted in the flush valve 10 includes the first integral ring 36, whichincludes a plurality of circumferentially spaced support grooves 52 (seeFIGS. 3 and 7). The support grooves 52 are in fluid communication withthe inlet opening 14. Each support groove 52 is only in fluidcommunication with a specific set of filter orifices 56. Each respectivesupport groove 52 and respective set of filter orifices 56 (see FIG. 3)are in fluid communication with a respective chamber 58, with thechambers 58 being separated from each other. A plurality of radiallyextending chamber walls 60, which are circumferentially spaced apartextend from the first integral ring 40 to sealing ring 34. The chambers58 are defined by two adjacent ones of the chamber walls 60, portions ofthe sealing ring 34, and the first integral ring 36, and include one ofthe support grooves 52 and a set of the filter orifices 56.

In one non-limiting embodiment of the invention, the body 27 of theflexible diaphragm 22 is made of an elastomeric material, whichincludes, but is not limited to, natural rubber, synthetic rubber,synthetic polymers, and thermoplastic elastomer resins. The centralpassageway 32 is defined by an inner perimeter of the body portion 28 toprovide the diaphragm 22 with has an annular-shaped. The support grooves52 (see FIG. 7) are substantially larger than filter passages 54 and donot provide any filtering function for the bypass orifice 50 (see FIG.3) or for the filter passages 54. The structure defining the supportgrooves 52 provides support for the flexible diaphragm 22. The filterpassages 54 are in fluid communication with a circumferential passageway64 (see FIG. 4) defined on the second side or top side 42 of flexiblediaphragm 22 as mounted in the flush valve. The circumferentialpassageway 64 includes a first dam wall 62 at a first end 72 adjacentone side of the exit chamber 48, a second dam wall 74 at a second end 76adjacent the other side of the exit chamber 48, and a plurality ofcircumferential supports 66 having flow through passages 68 (see FIG.7), which do not provide a filtering function. At least one flow pathorifice 70 is defined in the circumferential passageway 64 to directfiltered water to bypass chamber 46 (see FIG. 3) defined on first sideor bottom side 38 of flexible diaphragm 22 as mounted in the flushvalve.

In one non-limiting embodiment of the invention, there are two flow pathorifices 70, one adjacent to the first dam wall 62 and one adjacent tothe second dam wall 74 (see FIGS. 3 and 4). The filtered water passesthrough the bypass orifice 50, which has a flow area greater than filterpassages 54, but less than support grooves 52 (see FIG. 7), and thefiltered water is then directed to the high-pressure side (the secondside 42) of the flexible diaphragm 22. The outer peripheral sealing ring34 is defined on flexible diaphragm 22 and is radially spaced or offsetfrom the support grooves 52 and the filter passages 54. The supportgrooves 52 and the chambers 58 are not in fluid communication with eachother, in normal operation of flush valve 10, when the water or liquidflows from the support grooves 52 to the flow path orifices 70. In onenon-limiting embodiment, the size of the support grooves 52 isapproximately 0.060″ wide.times.0.070″ high. The sealing ring 34 thatextends along the outer periphery of diaphragm 22 forms a liquid sealwith the valve body 12, the top cap 80, and the inner cover 100 of theflush valve.

As shown in FIG. 4, the exit chamber 48 is defined by the first dam wall62, the second dam wall 74, a diverter shield 114, and includes at leastone exit passage 116 (two shown in FIG. 4), and the bypass orifice 50.The exit passages 116 are defined by the space between the first damwall 62 and the second dam wall 74 and the diverter shield 114. Thebypass orifice 50 is defined within the exit chamber 48 and thediaphragm 22 and is in fluid communication with the bypass chamber 46defined on the first side 38 of the flexible diaphragm 22. Withreference to FIGS. 3, 4 and 8, in the present arrangement of thenon-limiting embodiment under discussion, unfiltered water from inletopening 14 passes through the support grooves 52 (as shown by arrow A inFIG. 3), travels a serpentine path 118 shown in FIG. 8 that includespath C shown in FIG. 4, then exits as filtered water through exitchamber 48 (see FIGS. 5 and 6) on the second side 42 of the flexiblediaphragm 22 via exit passages 116 (see FIG. 8) into the pressurechamber 26 (one of the exit passageways 116 shown by arrow B in FIG. 4).By filtering, it is meant that filter passages 54 remove from the waterparticulates and debris that are larger than the diameter of filterpassage 54, so as to prevent clogging of bypass orifice 50, which has alarger diameter than filter passage 54.

The bypass chamber 46 (see FIGS. 5 and 6) is defined by a portion of thesealing ring 34, a portion of the first integral ring 36, a first endsupport 110, and a second end support 112. The end supports 110, 112extend from the sealing ring 34 to the first integral ring 36. Thebypass chamber 46 includes the bypass orifice 50 and at least one flowpath orifice 70 (see FIGS. 3 and 4).

The first integral ring 36, defining support grooves 52, providessupport for the diaphragm 22. The filter passages 54 are in fluidcommunication with the circumferential passageway 64 defined on thesecond side 42 of diaphragm 22. Water passing through the filterpassages 54 becomes filtered. The circumferential passageway 64 has aplurality of circumferential supports 66 having flow through passages 68which provide no filtering function and have a right triangular flowdimension of about 0.070″ high at the perpendicular leg and 0.085″ wideat the base (see FIG. 5). The circumferential supports 66 canalternatively have a U-shaped cross section. The two flow path orifices70 defined in the circumferential passageway 64 direct filtered water tothe bypass chamber 48 defined on the first side 38 of the diaphragm 22.The filtered water then passes through bypass the orifice 50, which hasa flow area greater than the filter passages 54, but less than thesupport grooves 52 and flows through the passages 68. Filtered water isthen directed to the high-pressure side (second side 42) of diaphragm 22adjacent pressure chamber 26. Although the bypass orifice 50 is shown tobe integrally formed in the body 27 of the diaphragm 22, a separateinsert having bypass orifices 50 can be provided and secured in thediaphragm 22. In a presently preferred embodiment, the diameter ofbypass orifice 50 is 0.020″ and the diameter of filter passage 54 is0.014″. The other flow paths have flow diameters greater than 0.020″.

The discussion is now directed to a general description of the operationof the flush valve. In a normally closed position, as is shown in FIG.1, water pressure P₁, which is greater than atmospheric pressure P₀, iscommunicated to pressure chamber 26 at inlet opening 14 through bypassorifice 50 (see FIGS. 3 and 4). Since the surfaces which are subjectedto the water pressure P₁ are greater on second side 42 of diaphragm 22(see FIG. 4), the water pressure forces diaphragm 22 down onto valveseat 20, preventing water from flowing through outlet opening 16.Referring to FIG. 2, when a user moves the handle 82 in any direction, aplunger 82 (see FIG. 1) moves inwardly, tilting the elongated stem 106of the relief valve 104. This action creates an opening 120 between thediaphragm 22 and the valve seat 20 releasing the pressure in thepressure chamber 26 by allowing water to flow through the barrel 78 asshown in FIG. 2. With the pressure in the pressure chamber 26 relieved,the water inlet pressure forces the diaphragm 22 to move upwardly, offof the valve seat 20, allowing water to flow directly from the inletopening 14, through the opening 120, the barrel 78, and the outletopening 16. When the diaphragm 22 and the relief valve 104 moveupwardly, the relief valve resets itself, closing off the pressurechamber. Water will then flow through the circumferentially spacedsupport grooves 52 (see FIG. 7) and through the respective set 56 of thefilter passages 54 (see FIG. 3). The water will then flow through thecircumferential passageway 64 and respective flow through the passages68 to the respective flow path orifices 70 via the path 118 (FIG. 8).The filtered water will flow downward to the first side 38 of thediaphragm 22 into the bypass chamber 46 and through the bypass orifice50. The filtered water then flows into the exit chamber 48 and the exitpassages 116 (see FIG. 3) into the pressure chamber 26 until thediaphragm 22 is again forced against the valve seat 20, thereby closingthe flush valve 10. During the closing of the flush valve 10, the barrelslide 24 moves downwardly with the diaphragm 22 and the outwardlyextended flexible flow ring 88. The flow ring 88 contacts the barrel 78,again thereby minimizing water hammer effects and acting as a first sealuntil the radially inwardly seating surface 86 is sealed against thevalve seat 20.

The superior filtering of water prior to the water flowing through thebypass orifice 50 prevents clogging of the bypass orifice 50. Further,the bypass orifice 50 includes a tapered hole arrangement, as disclosedin FIG. 6 and which is described in detail in the Verdecchia patent, toprevent clogging of the bypass orifice should the diameter of thefiltering passages 54 increase due to wear or tearing of the diaphragm22 and provide no filtering function, alternatively, a cylindrical holemay be provided.

In a non-limiting embodiment of the invention, and with reference toFIGS. 3 and 4, the chambers 58 are defined by a portion of the valvebody 12, the peripheral seal 30, the first side 38 of diaphragm 22, anda portion of the first integral ring 36. Flow of water into each chamber58 is only accomplished through a respective one of the support grooves52, and flow can only exit the chamber 26 via a respective set 56 offilter passages 54. Passageway 64 is defined by a portion of the secondside 42 of diaphragm 22, a portion of inner cover 100 (see FIG. 1), aportion of the second integral ring 40, which is coaxial with the firstintegral ring 36, the supports 66, the dam walls 62, 74, and a portionof the peripheral seal 30 (see FIGS. 2 and 3). Flow into the passageway64 can only occur via filter passages 54, and flow exiting thepassageway 64 can only occur through the flow path orifices 70. Thebypass chamber 46 is defined by a portion of the first side 38 ofdiaphragm 22, a portion of the valve body 12, first end support 110 (seeFIG. 8), second end support 112, portions of the peripheral seal 30, andthe integral ring 36. Flow into bypass chamber 46 can only occur via theflow path orifices 70, and flow exits the bypass chamber 46 via thebypass orifice 50. The exit chamber 48 is defined by a portion of theperipheral seal 30, a portion of the second side 42 of the diaphragm 22,the first and the second dam walls 62 and 74, respectively, the innercover 100, portions of the second integral ring 40, and the shield 114.Flow into the exit chamber 48 occurs via the bypass orifice 50 and exitsthe chamber 48 via the exit passages 116 into the pressure chamber 26.Fluid seals are formed between the interaction of the diaphragm 22 andrespective contacting or clamping surfaces of the valve body 12, top cap80, and inner cover 100.

With reference to FIGS. 6 and 7 as needed, in lieu of providing thefilter passages 54 defined in the diaphragm 22, the filtering takesplace via the plurality of the support grooves 52. In this arrangement,the support grooves 52 have an effective flow diameter less than thediameter of the bypass orifice 50. Further, the supports 66 (see FIG. 4)are eliminated so that all of the chambers 58 are in fluid communicationon the first side 38 of diaphragm 22. The circumferentially spacedpassages 54 and the flow path orifices 70 are eliminated so that thefiltered water would flow directly to the bypass orifice 50. Thisarrangement would utilize a unitary diaphragm filter arrangement asopposed to a two-piece arrangement.

The discussion is now directed to a non-limiting embodiment of thesegmented insert 29 (see FIGS. 9 and 10) surrounded by the flexible body27 (see FIGS. 3 and 4) to embed the segmented insert 29 in the flexiblebody 27 of the diaphragm 22.

FIGS. 9 and 10 illustrate a segmented insert 29 made in accordance withthe present invention. The segmented insert 29 is preferably made ofpolypropylene in any convenient manner, e.g. but not limited toinjection molding. The segmented insert 29 includes a plurality ofsegmented members 132 with protrusions 134 extending outward from side135 of the segmented members. As clearly shown in FIG. 9, but notlimiting to the invention each segmented member 132 has five protrusions134, although the number of protrusions or spacers 134 may be varied,e.g. the segments can have less than or more than five. Opposite side137 (see FIG. 10) of the segmented members 132 is preferably smooth,that is, has no protrusions extending therefrom. The protrusions 134 actas spacers during the molding process of the diaphragm 22. The segmentedmembers 132 have two side edges 138, 139, one inner edge 140 and oneouter edge 142 and can be trapezoidal in shape. The segmented member 132can preferably have the same geometric shape and can take the form ofother quadrilateral shapes as well as other shapes. Each of theplurality of segmented members 132 is connected on their respectiveouter edges 142 to inner surface of a runner or a closed ring 136 with aspace 143 between adjacent segmented member 132. In this manner, thecenter portion of the diaphragm 130 having the segmented insert 29 canbe flexed when the flush valve 10 moves from the is open position to theclosed position and vice versa. Preferably, the inner edges 142 definean annulus that has a diameter greater than the passageway diameter 32and the outer edges 142 define an outer diameter of the segmented insert29 that is less than the outer diameter of the diaphragm 22, so that thesegmented insert may be completely embedded within the flexible body 27of the diaphragm 22.

Referring to FIGS. 3 and 4, the insert 29 is integrally molded withinthe material of the flexible body 27 to provide the flexible diaphragm22. The flexible diaphragm 22 of the invention is more rigid than thediaphragm of the prior art, e.g. but not limited to the diaphragm ofU.S. Pat. No. 4,327,891 in the radial direction because of the segmentedinsert 29. As is evident, the segmented insert 29 is integrally fusedwith the material of the flexible body 27 so the segmented insert 29 isnot visually detectable by the outward appearance of the diaphragm 22.Preferably, the material of the flexible body 27 is made of anelastomeric polymer, more specifically, thermoplastic elastomer (TPE),and the TPE is injection molded around the segmented insert 29 to formthe diaphragm 22. It is preferable that the TPE is santaprene. Theprotrusions or spacers 134 of the segmented members assist in permittingthe TPE to flow around the segmented members 132 and protrusion 134 ofthe segmented insert 29. Polypropylene easily bonds to TPE. Optionally,the side 137 of the segmented members can have protrusions 134. Althoughnot shown, the segmented insert 29 need not be completely surrounded byTPE of the flexible body 27. In another preferred embodiment, thesegmented insert 29 is molded to the body, except side 137 of segmentedmembers is exposed and not covered by TPE.

FIGS. 11-13 illustrate a second embodiment of a segmented insert 29′made in accordance with the present invention which can be used in lieuof segmented insert 29. The segmented insert 29′ is preferably made ofpolypropylene in any convenient manner, e.g. but not limited toinjection molding. The segmented insert 29′ includes a plurality ofsegmented members 132′ with protrusions 134′ extending outward from side135′ of the segmented members. As clearly shown in FIG. 11, but notlimiting to the invention each segmented member 132′ has two protrusions134′, although the number of protrusions or spacers 134′ may be varied,e.g. the segments can have less than or more than two. Opposite side137′ (see FIG. 12) of the segmented members 132′ is preferably flat,that is, has no protrusions extending therefrom. The protrusions 134′act as spacers during the molding process of the diaphragm 22′. Thesegmented members 132′ have two side edges 138′, 139′, one inner edge140′ and one outer edge 142′ and can be substantially trapezoidal inshape. The segmented member 132′ can preferably have the same geometricshape and can take the form of other quadrilateral shapes as well asother shapes. Each of the plurality of segmented members 132′ isconnected on their respective outer edges 142′ to inner surface of arunner or a closed ring 136′ with a space 143′ between adjacentsegmented member 132′. In this manner, the center portion of thediaphragm 130′ having the segmented insert 29′ can be flexed when theflush valve 10′ moves from the is open position to the closed positionand vice versa. Preferably, the inner edges 140′ define an annulus thathas a diameter greater than the passageway diameter 32 and the outeredges 142′ define an outer diameter of the segmented insert 29′ that isless than the outer diameter of the diaphragm 22, so that the segmentedinsert may be completely embedded within the flexible body 27 of thediaphragm 22. As can be seen, an inner ring 150′ is formed and has twoconnectors 152′ attaching the inner ring to two respective segmentedmembers. But for connectors 152′, a space 145′ is defined between theinner edges 140′ and the inner ring 150′. The inner ring 150′ addsstability to the diaphragm 22. Likewise, an inner diameter 154 isgreater than the diameter of the passageway 32. The insert 29′ caneither be completely embedded within the body 27 or partially embeddedwithin the body 27 so that side 137 may be exposed. Preferably inserts29 and 29′ are molded as in integral piece.

The prior art diaphragms as discussed above, in general have rubbersurrounding and molded to a plurality of copper stiffeners. The presentinvention utilizes only one insert to facilitate injection molding.Further, the segmented insert 29 provides stiffening in the radialdirection while it permits flexibility of the diaphragm in thecircumferential direction C (see FIG. 4). The diaphragm of the presentinvention is preferably used above the valve seat in the free positionand resists downward motion to allow a soft/slow and noise resistantshut-off. The TPE utilized in the present invention is chloramineresistant as opposed to rubber. The TPE to polypropylene bondingprovided by the present invention better resists delamination thanrubber molded copper. Further polypropylene segments minimize leaks dueto the body 27 cracking from wear.

The present invention has been described with reference to specificdetails of particular embodiments thereof. It is not intended that suchdetails be regarded as limitations upon the scope of the inventionexcept insofar as and to the extent that they are included in theaccompanying claim.

1. A flush valve diaphragm comprising: a body having a flexible bodyportion and a segmented insert within the flexible body portion, thebody comprising: a central passageway; a peripheral sealing portioncomprising a sealing ring extending along the periphery of the body, thesealing portion with a thickness greater than the thickness of portionof the body within the sealing ring, wherein the flexible body portionis within the peripheral sealing portion; a first integral ring on afirst side of the body radially spaced from the sealing ring; a secondintegral ring on opposite second side of the body radially spaced fromthe sealing ring; an integral filter integrally formed in the bodylocated between the sealing ring and the first integral ring and betweenthe sealing ring and the second integral ring; a bypass chamberpositioned between the first integral ring and the sealing ring; an exitchamber positioned between the second integral ring and the sealingring; a bypass orifice extending from and allowing fluid communicationbetween the bypass chamber and the exit chamber; and the segmentedinsert comprising a plurality of trapezoidal members with protrusionsextending outward from a major surface of the trapezoidal members,wherein the plurality of trapezoidal members are connected to each otheron their outermost edge by a runner.
 2. The flush valve diaphragmaccording to claim 1, wherein the runner of the segmented insert is anendless runner and each of the trapezoidal members comprises a firstside and an opposite second side, the second side having a length lessthan the first side, the first side of each of the trapezoidal membersconnected to the endless runner and the second side of each of themembers in facing relationship to the central passageway of the body. 3.The flush valve diaphragm according to claim 1, wherein the segmentedinsert is made of plastic and each of the trapezoidal members comprisesa first major surface and an opposite second major surface, wherein theprotrusions extend from the first major surface and the second majorsurface is flat.
 4. The flush valve diaphragm according to claim 1,wherein the flexible body portion is made of a thermoplastic elastomer.5. The flush valve diaphragm according to claim 4, wherein the flexiblebody portion is made of a chloramine resistant thermoplastic elastomer.6. The flush valve diaphragm according to claim 5, wherein the flexiblebody portion is made of santaprene.
 7. The flush valve diaphragmaccording to claim 4, wherein the segmented insert is made ofpolypropylene.
 8. The flush valve diaphragm according to claim 4,wherein the segmented insert is made of polypropylene and the flexiblebody portion is made of santaprene.
 9. The flush valve diaphragmaccording to claim 8, wherein the runner of the segmented insert is anendless runner and each of the trapezoidal members comprises a firstside and an opposite second side, the second side having a length lessthan the first side, the first side of each of the trapezoidal membersconnected to the endless runner and the second side of each of themembers in facing relationship to the central passageway of the body.10. The flush valve diaphragm according to claim 9, wherein each of thetrapezoidal members comprises a first major surface and an oppositesecond major surface, wherein the protrusions extend from the firstmajor surface and the second major surface is flat.
 11. The flush valvediaphragm according to claim 1, wherein the segmented insert furthercomprises an inner ring attached to at least one of the trapezoidalmembers.
 12. In a flush valve diaphragm of the type having a flexiblerubber body and a metal insert embedded in the flexible rubber body, theflush valve diaphragm used with water closets and urinals, which utilizethe flexible diaphragm to establish, and to seal off, the connectionbetween inlet and outlet sides of a flush valve, the improvementcomprising; the flush valve diaphragm comprises a plastic segmentedinsert embedded in a body made of a thermoplastic elastomer, the plasticsegmented insert comprising a plurality of trapezoidal members withprotrusions extending outward from a major surface of the trapezoidalmembers, wherein the plurality of trapezoidal members are connected toeach other on their outermost edge by a runner.
 13. The flush valvediaphragm according to claim 12, wherein the runner is an endless runnerand each of the trapezoidal members comprises a first side and anopposite second side, the second side having a length less than thefirst side, the first side of each of the trapezoidal members connectedto the endless runner.
 14. The flush valve diaphragm according to claim13, wherein the body is made of a chloramine resistant thermoplasticelastomer.
 15. The flush valve diaphragm according to claim 14, whereinthe body is made of santaprene.
 16. The flush valve diaphragm accordingto claim 12, wherein the segmented insert is made of polypropylene. 17.The flush valve diaphragm according to claim 12, wherein the segmentedmember is made of polypropylene and the flexible body is made ofsantaprene.
 18. A flush valve diaphragm comprising: a body having aflexible body portion and a segmented insert within the flexible bodyportion, the body comprising: a central passageway; a peripheral sealingportion extending along the periphery of the body, and a bypass orificedefined by the body; and the segmented insert comprising a plurality ofmembers connected to each other and each of the plurality of memberscomprising a first side edge, an opposite second side edge, an outeredge and an opposite inner edge, wherein the plurality of members areconnected to one another at their outer edge such that the first sideedge and the second side edge of adjacent ones of the plurality ofmembers are spaced from one another.
 19. The flush valve diaphragm asclaimed in claim 18, wherein the segmented insert defines a centralannular portion having a first diameter which is greater than a diameterof the central passageway.
 20. The flush valve diaphragm as claimed inclaim 19, wherein the inner edge defines a portion of the annularportion and the outer edge defines an outermost edge of the segmentedinsert, wherein the outermost edge has a diameter less than an outerdiameter of the diaphragm.
 21. The flush valve diaphragm as claimed inclaim 20, wherein the members are attached to each other by a runner.22. The flush valve diaphragm as claimed in claim 21, wherein the runnerattaches the members at the second side of the member thereby forming anendless runner, and adjacent first sides of the members are spaced apartfrom each other.
 23. The flush valve diaphragm as claimed in claim 18,wherein the members are the same shape.
 24. The flush valve diaphragm asclaimed in claim 23, wherein the members are a geometric shape.
 25. Theflush valve diaphragm as claimed in claim 18 comprising: wherein theplurality of members each have the same quadrilateral shape.
 26. Theflush valve diaphragm as claimed in claim 25, wherein the quadrilateralis a trapezoid.
 27. The flush valve diaphragm as claimed in claim 18,wherein the plurality of members include a major surface havingprotrusions extending therefrom, wherein the protrusions have a heightless than the thickness of the diaphragm body adjacent to theprotrusions.
 28. The flush valve diaphragm as claimed in claim 18,wherein the flexible body portion is made of a different material thanthe material used in the segmented insert.
 29. The flush valve diaphragmas claimed in claim 28, wherein the segmented insert is completelyembedded within the flexible body portion.
 30. The flush valve diaphragmaccording to claim 18, wherein the segmented insert comprises an innerring attached to at least one of the members.
 31. A flush valve,comprising: a valve body defining an inlet opening and an outletopening; a valve seat positioned between the inlet and the outlet of theflush valve; a flush valve diaphragm assembly movable to a closingposition on the valve seat to stop flow between the inlet and theoutlet; and a diaphragm assembly positioned in the valve body andseparating the inlet and the outlet, with the diaphragm assemblyconfigured to have a pressure difference applied across the diaphragmassembly and said diaphragm assembly comprising: a body having aflexible body portion and a segmented insert within the flexible bodyportion, the body comprising: a central passageway; a peripheral sealingportion extending along the periphery of the body, and a bypass orificedefined by the body; and the segmented insert comprising a plurality ofmembers connected to each other and each of the plurality of memberscomprising a first side edge, an opposite second side edge, an outeredge and an opposite inner edge, wherein the plurality of members areconnected to one another at their outer edge such that the first sideedge and the second side edge of adjacent ones of the plurality ofmembers are spaced from one another and the inner edge of each of theplurality of members forms an opening having a diameter that is greaterthan a diameter of the central passageway.
 32. The flush valve diaphragmaccording to claim 31, wherein the segmented insert comprises an innerring attached to at least one of the members.